Dry cell machine



Feb. 24, 1942.

A. M. MaCFARLAND DRY CELL MACHINE Filed Dec. 24, 1958 4 Sheets-Sheet 1 Feb. 24, 1942. A, M MacFARLAND 42,274,490l

DRY CELL MACHINE Filed Dec. 24, 1938 4 Sheets-Sheet 2 o b 0 O o OOOOOOOOOOOOI Feb. 24, v1942.

A. M. MacFARLAND DRY-CELL MACHINE Filed Dec. 24, 1938 4 Sheets-Sheet 3 f@ MMQQ,

Feb.. 24, 1942. A.l M. MacFARLAND DRY CELL MACHINE Filed Dec. 24, 1938 4 sheets-sheet 4` ,m fm v Patented Feb. 24, 1942 by mesne assignments, to Burgess Battery Company, Chicago, Ill., a corporation of Delaware Application December 24, 193s, semi No. 247,726

(ci. zia- 4) t z claims.

This invention relates to machinery for the production of dry cells, and particularly to a machine for attaching metallic conductors to the cells to adapt; the cells to be used in multiple I cell batteries.

It is the object of the invention to provide a machine or mechanism in which the said function can be carried out in a reliable manner.

It is a further object of the invention to provide improved mechanism for performing such function which" is efficient in operation and operates without attention and has a long useful life.

It is the object of the invention to provide a mechanism for attaching such conductors by fusing such metal of thedry cells to the surface metal of the conductors by electrically-generated heat, and to provide a mechanism which is resistant to the heat whichgls involved in such operations and may be used for long periods without deterioration. Other objects and advantages will become apparent as the following description progresses, in which y f Fig. 1 is a plan view of the machine;

Fig. 2 is a second plan view of the machine on an enlarged scale with portions broken away;

Fig. 3 is a fractional, sectional view taken along line 3--3 of Fig. 2;

Fig. 4 is a side elevational view of the machine;

Fig. 5 is a fractional side elevational view showing the mechanism for feeding the conductor material to the dry cells;

' Fig. 6 is a view taken transversely of the machine and partly in section illustrating the mechanism for attaching the conductors to the cells; and

Fig. rlis a diagrammatic view showing the means for applying the electrical heating energy during the conductor-attaching operation.

The general features oi' the machine are illustrated in Fig. 1. It comprises a flat-topped main frame I supported upon legs Il. A pair of rotating `i'eed tables I2 are mounted upon frame I0. The operator first places the dry cells I2 on the feed tables. The cells are of the usual type having a positive terminal consisting of a central carbon rod having a brass cap and a negative terminal consisting of a cylindrical zinc container. From the feed tables i2,- the cells are fed to a reciprocating mechanism for advancing them intermittently in two separate rows (not shown in Fig. 1);y The cells of 'each row are operated upon individually by apparatus for testing separateLv their electrical potential and current delivery properties, and electing those which do not deliver predetermined minimum values. The details of this apparatus are not described herein. The upper parts .or shoes of the ejecting mechanism are indicated by the numeral il. The rejected cells i are lifted out of the line of advancing cells and pushed laterally upon a platform I8 above frame i0. The re- Jected cells I5y of the other row are delivered to a corresponding platform I6' on the other side of the machine. 'I'he satisfactory cellsil continue to be advanced intermittently to a further station where a rotary brush |93 cleans the surfaces of the zinc containers, and then to a further station where the lead wires I8 are automatically welded to the zinc containers, the wire being fed downwardly from reels i9 to the cell and then pressed. momentarily against the zinc containers by a disc-shaped electrode 20 which supplies electric heating energy to accomplish the welding. After this, the cells continue to be advanced intermittently along a pair of delivery compartments 2I, these compartments being arranged so as to turn the cells from an up-.

Cell advancementvand general operations Referring to Figs. 2 and 4, the main frame iii has a bracket' 22 (see Fig. 4) extending from one end thereof and upon this bracket is supported a motor 2l which supplies .the motive power for, l

substantially the entire machine.

The power is transmitted from the motor 23 to a main shaft 24 by transmission mechanism f which is not shown. The shaft 24 is mounted upon suitable bearings 25, 26 and 21 which are mounted on a bracket 2l dependingy from the- The shaft redirection indicated. by the arrow in frame lil, as shown in Fig. 5. volves in the F18. 2.

The worm 22 upon the-end of shaft 2l turns the worm gear ll which drives the feed table I2 and causes it torevolve inthe direction indicated by the arrow. A spur gear (not shown) is mounted on the same shaft with worm gear 38 and through a suitable train of gears indicated at 3|, 32 and 33, the movement of gear 38 is transmittedto the second feed table, which is caused to revolve in the opposite direction as indicated by the arrow thereon. Stationary guide bars 84 are supported ,above feed tables to guide the dry cells |3.

The cells |3 are placed in an upright position upon the feed tables and are moved by the latter into and along the channels formed between the guide bars to the ends thereof where reciprocating feed shoes 35 alternately advance one cell from each feed table in the longitudinal direc# tion of the machine. Feed shoes 38 are mounted at the ends of a bar 38 which is mounted pivotally at its center and has an oscillating motion transmitted to it in synchronism with the rest of the machine by means of a cam 31 on shaft 24, a pair of cam followers 38, adapted to reciprocate crosswise of the machine, link 48, and a lever 4| fastened to the oscillating bar 38 and adapted to transmit motion to the latter. The shoes .have concave surfaces adapted to hold the cells while moving them in the desired longitudinal direction.

From the point to which the cells are advanced by the feed shoes 38, they are further advanced intermittently in a longitudinal direction by racks 48, which are adapted to reciprocate longitudinally and transversely, and are held stationary at the different stations at which the operations are performed by other racks 41 which reciprocate transversely of the machine. These racks each have a series of semi-circular recesses. indicated at 48 lon rack 48, shaped to conform with the cylindrical surfaces of the dry cells, and adapted to engage the dry cells as will be described. This type of mechanism is not new with this invention and the detailsare not all shown. The racks 41 are mounted upon the longitudinally extending base member indicated generally at 8|, see also Fig. 11 .and the latter is adapted to be reciprocated transversely by transverse bars 48 and 88. There are two racks 41 for each row of cells, as shown in Fig. l1, one engaging the cells near the top and the other near the bottom. 'I'he same is true of racks 48. Racks 48 are mounted near their ends on lugs 88 and 81, of which only one set is shown in Fig. 2, these lugs also being fixed to transverse bars 48 and 80. The edges of the racks 48 are mounted slidably in slots in the lugs, as illustrated in Fig. 3, to permit longitudinal motion of the racks relative to the lugs. 'Ihe base portions 88 of the lugs are mounted slidably in transverse recesses 88 in the main frame I8 to permit transverse motion of the lugs. Transverse motion toward the right (when viewed in the direction of cell advancement) is transmitted to bars 48 and 88 by means of cam followers 82 and 88 which cooperate with cams 84 and 88 on shaft 24. Motion to the left is transmitted by compression springs 88 operating upon the lugs 88 and 81. For this purpose, lugs 8| aremounted in fixed position upon the frame |8 and rods 82 are mountedin the said lugs 88 and 81 and extend slidably into cooperating openings in lugs 8|. 'I'he compression springs -88 are mounted over the rodsv 82 and exert a force on lugs 88 and 81 suiiicient to move the bars 48 and 88 and the racks in the opposite undergo longitudinal motion in such manner as to advance the cells. For this purpose shaft 24 has mounted thereon a cam 18 having a cam recess 1| therein adapted to impart an oscillating motion to bar 12 which is mounted pivotally on the frame at 13. A cam follower (not shown) is provided at the end of bar 12 and is adapted to cooperate with cam groove 1|. Bars 12 are connected to racks 48 on both sides of the pivotal mounting 13 by means of link members 14. Transverse slots 18 in the ends of racks 48 cooperate with the link members 14 to permit the transverse motion of the racks.

The step-by-step advancement of the dry cells by means of the racks is accomplished in the following manner. The cells of each row are held against lateral movement by the longitudinally extending rails 18 which are fixed in position. In the position in which the machine is shown in Fig. 2, the racks 48 on the left side of the machine are approximately at the mid-point of their advance movement (the direction is indicated by the arrow) and the others are at the mid-point of their retractive movement. In its last previous motion, the right hand oscillating feed shoe 38 has moved the rearmost'dry cell 11 into position to be engaged in the rearmost recess of right hand racks 41, and the racks 41 haveA subsequently moved transversely so as to engage cell 11 and hold it and the rest of the cells of this row stationary while the operations are performed at the different stations. The right hand racks 48 have re'ceded from this row of cells, indicated generally by numeral 18, and are moving backward. With respect to the other row of cells 18 the left hand racks 48 have advanced to engage the cells and are moving them forward to their next succeeding stations, and are at approximately the mid-point of their forward movement. The cams on shaft 24 are arranged so that the transverse and longitudinal movements of the racks occur alternately, and upon completion of the longitudinal movement of racks 48, transverse bars 48 and 88 move all of the racks transversely and racks 41 engage the dry cells of row 18 and hold them in a stationary position while racks 48 engage the dry cells oi' row 18 and advance them to the next successive station.

Pin-wire attaching operation As the dry cells are advanced to the station indicated at |88 and in Figs. 1 and 2, the upper portion of the zinc cans, on the side disposed toward the middle of the machine, are subjected to a brushing operation by means of wire brush |88. Thisbrush is molmted on the end of arm 288 which is mounted pivotally at the other end direction as the surfaces of cams 84 and 88 recede.

During the time that racks 48 are in engagement with the dry cells. as shown in F18- 2. they on base member 8|, and is operated by motor 28|l see Fig. 4, by means of the pulley and belt system 282, 288, 284, 288 'and 288. As the base member 8| reciprocates transversely, the arm 288 reciprocates with it and cooperates with belt 288 to vpress brush |88 against-cells in both rows with resilient pressure. The brushing removes any coating of dirt or oxide which may be present and prepares a clean zinc surface for the attachment of the wire conductor 281, called pin-wire, which is used for connecting the cells together in a multiple cell battery.

Asthe dry cells are advanced in the machine. the next operation is the attachment of the pinwires. This is accomplished by arranging the pin-wire adjacent the upper portion of the zinc can of each cell and momentarily pressing a disc conductor, preferably of carbon. against-the opposite side of the wire with resilient pressure and simultaneously passing electrical current from the disc through the wire and the adiacent portionfof the zinc can whereby suiiicient heat is generated at the Junctions between these parts and in the wire to cause the wire to welded to the zinc surface. 'Ihe wire is usually of copper with a surface coating of tin, and the heat is such as to fuse the tin of the coating and the zinc of the can to cause the' tw'o' to weld together. l V

I'he wire 231 for each row of cells is fed from the reel I3, mounted at the top of the machine (see Fig. 4), by means of mechanism contained in housing 2|2, and shown in detail imm. 5. The wire is fed downwardly into` the housing 2|2 through an opening and guide member 2|4 in the top of the latter and passes around pulleys 2|3 and 2|3. The upper portion 2|3 of housing 2 2 is a container for a flux which may be a solutionof ammonium chloride, 'zinc chloride and starch and the wire becomes coated with -ux as it passes through the container 2|3. From pulley 2|3 the wire passes downwardly through a second guide member 2|1 and between two rollers 2|3 and 2|9, between which the wire is grasped by compression and caused to advance in astep-by-step movement a regulated distance at each step. Roller 2| 3 is mounted in a bearing block which is urged toward roller 2|3 by means of spring 22|, the compression of which may be regulated to control the compression exerted upon the wire. Roller 2|3'turns freely..ahd

roller 2|3 is driven by an-oscillating crank 222 mounted on the outside of housing 2|2 and connected to the roller 2|3 by mechanism which .is not shown, but which may be of the u'sual type for driving the roller in one direction only and permitting the crank to move freely in the opposite direction. This may be a ratchet and pawl` mechanism or a spring mechanism after theconstruction oi' so-called free-wheeling mechanisms. Crank 222 is oscillated by means oi' rod 223 through the interposition of bell crank lever zu and link 225. A cam follower :is and rod 223 isxmoved downwardly by cam- 221 and upwardly by spring 223 mounted in compression about rod 223 and exerting pressure against lever 224. From the feeding mechanism the wire passes through a `third guide member 243 andinto adjacent relation to the vzinc can of dry ceu zio. y

Means are provided for severing each length oi' Wire as it is fed. Crank 222 has a projecting surface 233 which cooperates with the enlargement, or catch 23|, at the end of lever 232 which is connected to lever 233, both levers beingmounted pivotally at 234. The lever 232 is held against the surface of the crank by the spring 233. Mounted inside of housing 2|2 and moving `with levers 232 and 233 is a bar 233 having a dog (not shown) is carried by the left end of bar 233. The lever 232 is engaged by the pro- Jecting surface 233 during the `iirst part oniyoi' the stroke of crank 222 during which the crank 222 `moves in the direction indicated by the ai'-k row, which is'the return stroke with respect to the feeding of the wire 2| 3. nie levers `232 and ward the rightas it is viewed in Fig. 5. The

`surfaces ofcrank 222 and lever 232 are shaped so as to causek disengagement before the completion of the return stroke, as shown in Fig. 5, and compression spring 233 moves the cutting bar 233 toward the leftand the blade enters an opening in guide member 243 to sever the wire. Before the completion of the feed` stroke, catch 23| snaps into engagement with projecting 'sur-1 face 233 again; Adjustable stop member 223 reg- .insulating material 233l which is fastened toy transverse .bars 43 and 33. The cell-holding racks 41 are mountedfupon base 3|l by means of supporting rods 24|. A housing 242 is mounted upon 3|. in such manner that it is slidablej transversely with respect to said base. the housing being urged to a mid-position by means -ot springs 233 which are contained in a transverse opening 233 in basev 3|. Carbon disc 23 is mounted upon an upright spindle 243 which is Journaled in housing 242. Spindle 243 carries a worm gear 243 beneath carbon disc 20, and housing 242 carries a worm 243 adapted to cooperate withworm gear 243, and a ratchet 243 adapted to turn worm 243. Upon the same shaft carrying worm 243 and ratchet 243 is rotatably mounted a pawl mechanism comprising arm 230 and pawl 23|, the pawl being carried by the arm and pressed by means oi' aspring against the surface of the ratchet and adapted to turn the latter in the well known manner. A second pawl 233 is mounted on the housing 242 and is adapted to prevent backward movement of ratchet 243 with backward movement of arm 233. Two stop members 241 are mounted in fixed positions upon the base 3|, and two additional stop members 232 in adjustable positions upon stationary bar 233, which is mounted on the frame of the machine. `The lateral positions of stops 232 may be adjusted by loosening the bolts 234, slots 233 being provided in thelangular portions of the stop members for the purpose of permitting adjustment.

A The mechanical operation of the carbon disc 23 is as follows. As the base 3| reciprocates laterally, it carries with itr the housing 242, the movement of the ylatter being due to the f orce exerted by the springs 233. In its' lateral movement. the edge of the disc engages vvthewire 231 and presses the latter momentarily against the dry cell. 2|3. The wirel 231 carries a coating of flux as described heretofore and during this moment electric energy is applied, as will be explained hereinafter, Awhich causes the wire to be welded by heat to'the zinc can of cell 2|3.

'The movement of the disc is stopped and with 241 upon the base, the arm 233 is caused to undergo a small rotary motion which it transmits by means of pawl 23| to the ratchet 243. Operation of the ratchet causes turning of worm m'andrworm gear 243 with the result that the 233 during this time move cutting bar 233 to- 23 carbon disc is rotated a small increment-this being regulated to result in a circumferential movement of the edge of the disc a distance approximating the diameter of thewire 2l5. The

stops 252 are adapted to stop the lateral movement of the carbon disc in the absence of a dry cell which may have been ejected, or which may be absent due to other causes, so that the relative movement between the base 5 l, and housing 242 and the resulting turning of the carbon disc, is obtained when the cell is absent as well as when it is present. The stops 252 are located so as to permit a slightly greater movement of.

the carbon disc than will take place in the presence of a dry cell. It is important that the carbon disc be rotated during operation so as to prevent vthe welding operation taking place at the same portion of its surface every time, which would result in the surface becoming overheated and destroyed at this point within a short.

time. By presenting a fresh welding surface each time the useful life of the carbon disc is prolonged many fold.

Means are provided for stopping the feed of the wire 201 in the absence of a dry cell, to prevent wastage of the wire and its accumulation in the machine. As has been pointed out above,

-the dry cell may be absent because it has not been fed by the operator or because it has been ejected by the testing mechanism described heretofore. The feed stopping means comprises a finger member 215, see Fig. 2, which is mounted pivotally at 218 on the machine and which is cooperatively associated with a switch 211 in an electrical supply circuit comprising conductors 215 adapted to supply electrical energy from a source indicated at 219 to a solenoid magnet 280, see Fig. 5, which is adapted to lock the wire feeding mechanism. in the inoperative position. The armature of the solenoid is connected to an arm 282 which, in turn, is fastened to a locking bar 253 which is adapted to be engaged in a notch 284 in the lower end portion of the rod 223 which operates the wire feeding mechanism. Atensionspring 255 is also fastened to locking bar 283 and tends to draw said bar out of the notch 255.

'I'he switch 211 is of the same character as the switches described heretofore and is normally in the closed position. 'I'he dry cells as they move in succession into position for the welding operation engage the finger member 215 and cause it'to turn slightly on its pivotal support 216 and actuate the operating member of switch 211 to open the said switch. The solenoid magnet 255 remains deenergized and the locking bar 255 is held out of the notch 254 by springI member Y255. When a dry cell is absent the finger member. 215 is not turned and the switch 211 remains closed and magnet 255 is actuated to draw the lock-ing bar 255 to the rightand. into the notch of operating member 225. This operating member is normally moved upwardly by spring 225, as has been described heretofore, but this upward motion is prevented when locking bar 255 is engaged in notch 255, and as a result wire 251 is not fed whenY a dry cell is absent from the welding position. The finger member 215 is shaped in such a way that it holds switch 211 open continuously when cells are present in each successive location, and allows the switch to close only when a cell is absent.

As in all of the operations described previously, the transverse movement of the carbon disc and the advancement of the dry cells 251 are synchronired so that the disc is pressed against the wire and the cell during the time that it is stationary. 'I'he electrical circuit for the welding operation, which is illustratedI diagrammatically in Fig. '1, is arranged to close the circuit only momentarily but this period, nevertheless, is long enough to generate sumcient heat at the Junctlon of the carbon disc and the wire. due tothe electrical resistance at this Junction, tofuse some of the zinc atthe surface of the can and the tin coating of the wire together.- The wire becomes embedded somewhat -in the zinc and the latter forms illlets against the wire. Ihe circuit is disconnected before the carbon disc undergoes its retractive movement so that the pressure is maintained between the wire 251 and the dry cell 2i5 while solidification and cooling of the metal occurs at the joint. The electrical energy supply comprises a source indicated at 255, a transformer primary 255 and a switch 255, of the character previously described and which is normally closed. connected in series. A cam 251 which is also mounted on shaft |55, rotates in synchronism with the machine to operate switch open-ing member 255 at the proper time. `Electrical energy is conducted from the transformer 259 through conductor 215 to the carbon disc 25. The conductor 215 is connected to the housing 252. see Fig. 6, which is in electrical connection with the carbon disc through spindle'255.

The electrical energy passes through the carbon disc, the wire 251, the dry cell can 2 I5 and thence returns through the ground to the secondary 259. As has been described heretofore, the frame ill upon which the dry cells are supported is connected to the ground. The apparatus is illusstrated in the operative position in Fig. 1.

The parts are synchronized so as to maintain the circuit closed during the first portion of the time that the carbon disc presses against the wire and the cell. After the circuit has been disconnected the disc continues to press the wire and the cell together with the result that the latter cool and the metal which has become liquefied during the heating momentis permitted to solidify while the pressure is maintained. thus providing a permanent electrical Joint. Experience with a machine of the character described shows' that unsatisfactory joints are produced so seldom that this factor is negligible. 'Ihe wire 251 may be in the form oi' nat strip metal instead of round wire.

As has been described heretofore, after the pin-wires have been welded to the cells the latter continue to be advanced by the machine forwardly between the rails 15 and into the compartments 2|"where they are turned from an upright to a horizontal position and finally rolled conductors to the zinc containers of dry cells comprising means for advancing said zinc contains in succession in two rows in an intermittent movement and maintaining said containers momentarily stationary at stations substantially opposite one another, a disc-shaped carbon electrode mounted between said rows ot containers and between a pair of said substantially opposite stationsI means for inserting elongated conductors between said carbon disc and said containers, a source of electric energy, means for re- 2. In a machine for welding articles, means for advancing said articles in succession in two rows and maintaining said articles momentarily sta.- tionary at stations substantially opposite one another, a welding electrode between said substantially opposite stations, means for reciproeating said electrode between said opposite stations and alternately into pressure engagement with the articles located at said opposite stations lcontainer at the pressure engagement with each i0 respectively.

successive container in the same row.

- ALLISON M. MACFARLAND. 

